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Limitorque LY Series Installation And Maintenance Manual

Actuation systems
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LMAIM1501
(
Replaces 150-12000)
Limitorque Actuation Systems
November 2003
50 100
0
Limitorque
LY Series
®
Installation and Maintenance
for LY 1001, LY 2001 and LY 3001

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Summary of Contents for Limitorque LY Series

  • Page 1 LMAIM1501 Replaces 150-12000) Limitorque Actuation Systems November 2003 50 100 Limitorque LY Series ® Installation and Maintenance for LY 1001, LY 2001 and LY 3001...
  • Page 2 However, Limitorque’s sales team and application engineers are always available to assist you in making your decision. This manual contains information that is correct to the best of Limitorque’s knowledge. It is intended to be a guide and should not be considered as a sole source of technical instruction, replacing good technical judgment, since all possible situations cannot be anticipated.

  • Page 3: Table Of Contents

    Flow Control Division Limitorque Actuation Systems Table of Contents 1 Introduction 1.1 Purpose 1.2 User Safety 2 Product Capabilities and Features 3 Initial Inspection and Storage Instructions 3.1 Product Identification 3.2 Inspection and Recording 3.3 Storage Procedures 3.3.1 Short-Term Storage (less than 1 year) 3.3.2 Long-Term Storage (1 to 5 years)
  • Page 4 Flow Control Division Limitorque Actuation Systems 7 Maintenance 7.1 Lubrication 7.1.1 Lubrication Inspection 7.1.2 Factory Lubricant 7.2 Minimum Lubricant Qualities Required 7.3 Disassembly and Reassembly 7.3.1 LY 1001 Disassembly 7.3.2 LY 1001 Reassembly 7.3.3 LY 2001/3001 Disassembly 7.3.4 LY 2001/3001 Reassembly 7.4 Troubleshooting...
  • Page 5 Flow Control Division Limitorque Actuation Systems Figure 6.9 – LY 2001/3001 Top Plate and Associated Parts 6-12 Figure 6.10 – LY 2001/3001 Housing and Associated Parts 6-13 Figure 6.11 – LY 3001 Handwheel Assembly 6-14 Figure 6.12 – LY 1001 Declutch Return Spring Installation Position Figure 6.13 –...
  • Page 6 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 7: Introduction

    Flow Control Division Limitorque Actuation Systems Introduction Purpose This Installation and Maintenance Manual explains how to install and maintain LY actuators. Information on installation, disassembly, lubrication, and parts is provided. User Safety Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment.
  • Page 8 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 9: Product Capabilities And Features

    LY actuators may be mounted on any size valve in almost any position or location. Microprocessor-based control and monitoring devices are available for installation on your actuator. Contact your local Limitorque distributor or Limitorque sales office for further information. Figure 2.1 – LY Actuator (LY 1001 shown)
  • Page 10 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 11: Initial Inspection And Storage Instructions

    Flow Control Division Limitorque Actuation Systems Initial Inspection and Storage Instructions a WARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to store the actuator. Be aware of electrical hazards within the actuator and high-pressure hazards of the attached valve or other actuated device when installing or performing maintenance on your LY actuator.

  • Page 12: Storage Procedures

    This condensation may occur with rapid temperature changes in the storage environment. If reliable means are not available to prevent rapid temperature changes, a heat source should be added in the electrical enclosure during storage. Consult the Limitorque Customer Service Department for further information.

  • Page 13: Unit Weights

    Flow Control Division Limitorque Actuation Systems Unit Weights The approximate LY actuator weights are provided below. Table 4.1 – Unit Weights Unit Size Control LY 1001 LY 2001 LY 3001 LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001...
  • Page 14 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 15: Installation Instructions

    If Torque Nut has not been bored and keywayed by Limitorque, it is provided solid (blank) to allow customer to custom key and bore up to the maximum permissible sizes as listed in Table 5.1.

  • Page 16: Installation Overview

    Flow Control Division Limitorque Actuation Systems Table 5.1 – Torque Drive Nut Custom Bore and Keyway Sizes Unit Type Maximum Bore Maximum Keyway and Size inch (mm) inch (mm) 1¹ ₈ dia (28 dia) ¹ ₄ x ¹ ₈ (6 x 3) LY 1001 2³...

  • Page 17: Figure 5.3 - Ly 1001, 2001, And 3001 Torque Drive Nut Orientation

    Flow Control Division Limitorque Actuation Systems Figure 5.3 – LY 1001, 2001, and 3001 Torque Drive Nut Orientation #32 Torque CCW to Open Torque Nut Stop Lugs Stop Lug Mechanical Stop Actuator index lines Setscrews Mounting facing Base Closed Open...

  • Page 18: Figure 5.4 - Removing Control Cover And Conduit Pipe Plugs

    Flow Control Division Limitorque Actuation Systems Insert the Retaining Drive Ring (piece #165 for LY 1001, piece #109 for LY 2001/3001) on the Torque Nut (piece #32) to hold the Torque Nut in place in the actuator. Mount the LY actuator on the mounting flange of the valve or other actuated equipment. High-strength (minimum SAE-Grade 5 120,000 psi tensile strength) hex head or socket head cap screws with lockwashers are recommended.

  • Page 19: Figure 5.5 - Grounding Lug Location

    Flow Control Division Limitorque Actuation Systems Table 5.3 – Control Cover and Conduit Pipe Plug Hardware Unit Type Control Cover Conduit Pipe Plug Quantity Size Quantity Size LY 1001 (WP & XP) 6 M8 x 40 mm 1” NPT Socket...

  • Page 20: Torque Switch Settings

    LY series actuators are typically supplied with a CCW Drive Sleeve rotation to open a valve. The Torque Switch is marked OPEN (CCW) and CLOSE (CW) based upon CW Drive Sleeve rotation to close the valve. The Mechanical Dial Position Indicator (MDPI) is typically mounted for CW rotation to indicate the CLOSED position.

  • Page 21: Limit Switch And Mechanical Stop Settings

    Flow Control Division Limitorque Actuation Systems Limit Switch and Mechanical Stop Settings The Limit Switch and Mechanical Stops are not preset at the factory, but must be set after mounting on the associated equipment. If the actuator has been shipped already installed on a valve, the actuator should have the Limit Switch and Mechanical Stops set for your application.

  • Page 22: Figure 5.7 - Limit Switch Setting Nut

    Flow Control Division Limitorque Actuation Systems Figure 5.7 – Limit Switch Setting Nut 7-10 Standard OPEN Microswitch location Standard CLOSE Microswitch location Rotate the CLOSE Limit Cam CW through the high side to the trip point until the Switch Plunger is released.

  • Page 23: Setting The Open Limit Switch

    Flow Control Division Limitorque Actuation Systems 5.7.2 Setting the OPEN Limit Switch NOTE: When setting the OPEN Limit Switch, be careful not to rotate the CLOSE Limit Cam; rotating it will change the adjustments you previously made on the CLOSE Limit Switch.

  • Page 24: Mechanical Stops

    Flow Control Division Limitorque Actuation Systems Mechanical Stops 5.8.1 Setting the CLOSED Mechanical Stop on the LY 1001 Table 5.5 – Mechanical Stop Set Screws Unit Mechanical Stop Set Screw Type Set Screw Size Size LY 1001 3/8-16 x 1.25”...

  • Page 25: Setting The Closed Mechanical Stop On The Ly 2001/3001

    Flow Control Division Limitorque Actuation Systems 5.8.2 Setting the CLOSED Mechanical Stop on the LY 2001/3001 Table 5.6 – Mechanical Stop and Locknut Screw Sizes Unit Type Stop Screw Size Locking Nut Size ⁵ ₈-16 x 3” ⁵ ₈-11 LY 2001/3001 All piece numbers refer to Figure 5.11.

  • Page 26: Setting The Open Mechanical Stop On The Ly 1001

    Flow Control Division Limitorque Actuation Systems 5.8.3 Setting the OPEN Mechanical Stop on the LY 1001 Piece numbers refer to Figure 5.10. With the valve in the full OPEN position, set OPEN Mechanical Stop Set Screw (piece #58) by removing the Set Screw (piece #59). (See Figure 5.9 for orientation.) Using the Handwheel, turn the valve to the OPEN position.

  • Page 27: Setting The Potentiometer

    Flow Control Division Limitorque Actuation Systems Figure 5.12 – Aligning MDPI with Dial Window Retaining Plate #108 MDPI Retaining Plate arrow #147 Screw 50 100 #146 MDPI Dial Plate PERCENT OPEN Limitorque 5.9.1 Setting the Potentiometer If the LY actuator includes a Feedback Potentiometer used for remote valve position indication, use an ohmmeter to calibrate the position of the potentiometer.

  • Page 28: Figure 5.13 - Potentiometer Calibration Components

    Flow Control Division Limitorque Actuation Systems Figure 5.13 – Potentiometer Calibration Components Potentiometer Shaft 50 100 Spur Gear PERCENT OPEN Limitorque Setscrew Potentiometer End Connection Drive Gear Center Connection Ohmmeter to Pot Leads If the reading is not correct, proceed to Step 5. If the reading is correct, proceed to Step 6.

  • Page 29: Operation

    Flow Control Division Limitorque Actuation Systems Operation Typical LY 1001 Operation LY actuators are always available for motor operation when the motor is energized. NOTE: Applied voltage rating = voltage rating of actuator ±10% a WARNING: Do not manually operate the actuator with devices other than installed Handwheel and Declutch Lever.

  • Page 30: Figure 6.1 - Standard Actuator/Three-Phase

    Flow Control Division Limitorque Actuation Systems b. If the actuator moves toward OPEN, the motor is wired properly for the application. Figure 6.1 – Standard Actuator/Three-Phase PUR/WHT PUR/WHT RED/BLK RED/BLK LIMIT SWITCH YEL/WHT YEL/WHT BLU/WHT BLU/WHT MOTOR PUR/WHT RED/BLK TH.OL...

  • Page 31: Figure 6.2 - Three-Phase With Control Package

    Flow Control Division Limitorque Actuation Systems Figure 6.2 – Three-Phase with Control Package PUR/WHT PUR/WHT RED/BLK RED/BLK LIMIT SWITCH YEL/WHT YEL/WHT MOTOR BLU/WHT BLU/WH T PUR/WHT RED/BLK TH.OL YEL/WHT BLU/WHT BLU/RED TORQUE YEL/BLK YEL/BLK SWITCHES TS18 /RED BLU/BLK BLU/BLK BLU/BLK...

  • Page 32: Single-Phase Motor

    Flow Control Division Limitorque Actuation Systems 6.2.2 Single-Phase Motor NOTE: Your application may vary from the standard wiring configuration for the single-phase motor shown in Figures 6.3 and 6.4. Refer to the specific actuator wiring diagram for wiring configuration. Using the Handwheel, move the valve to a midtravel position. Midtravel position allows electrical operation in the valve “safe”...

  • Page 33: Figure 6.3 - Standard Actuator/Single-Phase

    Flow Control Division Limitorque Actuation Systems Figure 6.3 – Standard Actuator/Single-Phase Valve shown in full open position 1 ph Limit Switch Contact Development MOTO R VALVE POSITION LIMIT SWITCH FUNCTION FULL FULL CONTACT OPEN CLOSE OPEN LIMIT INDICATION INDICATION CLOSED LIMIT INDICATION TS17 —Closing torque switch interrupts...

  • Page 34: Figure 6.4 - Single-Phase With Control Package

    Flow Control Division Limitorque Actuation Systems Figure 6.4 – Single-Phase with Control Package Valve shown in full open position MOTOR Limit Switch Contact Development CAP. (OPTIONAL ) VALVE POSITION L2 (T3) LIMIT TB1-8 SWITCH FUNCTION FULL FULL CONTACT TB1-9 OPEN...

  • Page 35: Dc Motor

    Flow Control Division Limitorque Actuation Systems 6.2.3 DC Motor NOTE: Your application may vary from the standard wiring configuration for the DC motor. Refer to the specific actuator wiring diagram for wiring configuration. Using the Handwheel, move the valve to a midtravel position. Midtravel position allows electrical operation in the valve “safe”...

  • Page 36: Motor Operation

    Flow Control Division Limitorque Actuation Systems Motor Operation CAUTION: Do not force the Declutch Lever into motor operation. Lever will automatically return to motor opera- tion when the motor is energized. Piece numbers refer to Figures 6.5, 6.6, and 6.7 for LY 1001, and Figures 6.8, 6.9, 6.10, and 6.11 for LY 2001/3001.

  • Page 37: Figure 6.6 - Ly 1001 Top Plate And Associated Parts

    Flow Control Division Limitorque Actuation Systems Figure 6.6 – LY 1001 Top Plate and Associated Parts 147, 148 Note: Rotate CW 180° for mounting Note: Refer to certified data for construction purposes 01-458-0020-4 Rev C. LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001...

  • Page 38: Figure 6.7 - Ly 1001 Housing And Associated Parts

    Flow Control Division Limitorque Actuation Systems Figure 6.7 – LY 1001 Housing and Associated Parts 22, 23 99, 100 20, 21, 30 40, 94 15, 18 Worm Shaft Assembl y Note: Refer to certified data for construction purposes 01-458-0020-4 Rev C.

  • Page 39: Figure 6.8 - Ly 2001/3001 Cover And Associated Parts

    Flow Control Division Limitorque Actuation Systems Figure 6.8 – LY 2001/3001 Cover and Associated Parts Note: Refer to certified data for construction purposes 101-458-0019-4 Rev A. LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 6-11...

  • Page 40: Figure 6.9 - Ly 2001/3001 Top Plate And Associated Parts

    Flow Control Division Limitorque Actuation Systems Figure 6.9 – LY 2001/3001 Top Plate and Associated Parts 147, 148 9, 111 Note: Refer to certified data for construction purposes 101-458-0019-4 Rev A. 6-12 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001...

  • Page 41: Figure 6.10 - Ly 2001/3001 Housing And Associated Parts

    Flow Control Division Limitorque Actuation Systems Figure 6.10 – LY 2001/3001 Housing and Associated Parts 21,29,55 20,30 22,23 99,100 15,118 Worm Shaft 114 113 Assembl y Note: Refer to certified data for construction purposes 01-458-0019-4 Rev A. LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001...
  • Page 42 Flow Control Division Limitorque Actuation Systems Figure 6.11 – LY 3001 Handwheel Assembly Note: Refer to certified data for construction purposes 01-458-0019-4 Rev A. 6-14 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 43: Maintenance

    7.1.1 Lubrication Inspection Inspect Limitorque LY series actuators for correct lubrication prior to operating—particularly following a long storage period. Each application has its own effect on the actuator and the frequency of these inspections should be based on the application and the operating experience.

  • Page 44: Disassembly And Reassembly

    Flow Control Division Limitorque Actuation Systems The lubricant must • have “EP” properties. • be suitable for the temperature range intended. • be water and heat-resistant and non-separating. • not create more than 8% swell in Buna N or Viton.

  • Page 45: Ly 1001 Reassembly

    Worm Shaft Assembly. In the event that the Worm is stripped, the Worm Shaft Assembly will need to be completely replaced. NOTE: If Light Spring Pack or Heavy Spring Pack replacement is necessary, contact your Limitorque authorized dealer or the Limitorque Service Department for a complete Worm Shaft Assembly replacement.
  • Page 46 Flow Control Division Limitorque Actuation Systems Figure 7.1 – LY 1001 Declutch Return Spring Installation Position #47 Declutch Return Spring Bottom 6301 . 6301 . Declutch Fork LY 1001 Top View LY 1001 End View Install Declutch Assembly (piece #46, 123, 44, and 55).

  • Page 47: Ly 2001/3001 Disassembly

    Flow Control Division Limitorque Actuation Systems Install Input Worm Motor Pinion Assembly 18. Install Input Worm Motor Pinion Assembly (pieces #52, 156, 53, 124, and 31) into the Housing. 19. Install Housing Seal (O-Ring) (pieces #131). Grease Unit 20. Grease unit with the properly recommended grease. (See Section 7.1, Lubrication.) Install Top Plate 21.
  • Page 48 Worm Shaft Assembly. In the event that the Worm is stripped, the Worm Shaft Assembly will need to be completely replaced. NOTE: If Light Spring Pack or Heavy Spring Pack replacement is necessary, contact your Limitorque authorized dealer or the Limitorque Service Department for a complete Worm Shaft Assembly replacement.

  • Page 49: Ly 2001/3001 Reassembly

    Flow Control Division Limitorque Actuation Systems 7.3.4 LY 2001/3001 Reassembly a DANGER: HAZARDOUS VOLTAGE. Turn off all power before assembling the LY actuator. Piece numbers refer to Figures 6.8, 6.9, 6.10, and 6.11. Install Input Worm Gear Install Input Worm Gear (piece #18).
  • Page 50 Flow Control Division Limitorque Actuation Systems Install Handwheel Assembly 12. Install the Clutch Sleeve (piece #13), ensuring the Declutch Fork Assembly (piece #46) is between the Input Worm Gear (piece #18) and the Clutch Sleeve (piece #13). 13. Install Thrust Washer (piece #26), Thrust Bearing (piece #27) and second Thrust Washer (piece #26) into the Handwheel Clutch (piece #16).

  • Page 51: Troubleshooting

    Flow Control Division Limitorque Actuation Systems Troubleshooting a WARNING: Be aware of electrical hazards within the actuator and high-pressure hazards of the attached valve or other actuated device when installing or performing maintenance on the LY actuator. Symptom Possible Cause...
  • Page 52 Flow Control Division Limitorque Actuation Systems Symptom Possible Cause Corrective Action Motor runs, but no Damaged gearing Disassemble actuator in output from unit accordance with Section 7.3.1, Disassemble Unit LY 1001 or Section 7.3.3, Disassemble Unit LY 2001/3001 as applicable. Inspect gearing for rough or damaged spots.
  • Page 53 Flow Control Division Limitorque Actuation Systems Symptom Possible Cause Corrective Action Reversing Starter failure Excessive cycling (too Review application to determine frequent operation) number of starts per hour and review with factory if more than 100 per hour. Excessive current draw...
  • Page 54 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. 7-12 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 55: Parts Lists

    Flow Control Division Limitorque Actuation Systems Parts Lists Table 8.1 – LY 1001 Parts List (Refer to Figures 6.5, 6.6 and 6.7) Piece # Description Piece # Description LY 1001 Housing Retaining Washer Top Plate Hex Head Cap Screw Control Cover...

  • Page 56: Table 8.2 - Ly 2001/3001 Parts List

    Flow Control Division Limitorque Actuation Systems Table 8.1 – LY 1001 Parts List (continued) Piece # Description Piece # Description Roll Pin Spring Spacer* O-Ring – Motor Compression Spring Quad Ring Handwheel Washer O-Ring (3 mm) Spacer – Worm Shaft –...
  • Page 57 Flow Control Division Limitorque Actuation Systems Table 8.2 – LY 2001/3001 Parts List (continued) Piece # Description Piece # Description Declutch Lever Worm Drive Clamp Varies Return Spring Dowel Pin Socket Head Cap Screw Compression Spring Lockwasher Declutch Latch – Right Input Gear –...
  • Page 58 Flow Control Division Limitorque Actuation Systems Table 8.2 – LY 2001/3001 Parts List (continued) Piece # Description Piece # Description Drive Screw Roll Pin Grounding Lug Declutch Lever Plate Hex Head Cap Screw Drive Screw Lockwasher Cheater Bar Warning Label...

  • Page 59: How To Order Parts

    Flow Control Division Limitorque Actuation Systems How to Order Parts To order parts or obtain further information for your Limitorque LY valve actuators, contact your local Limitorque distributor sales office, or: Limitorque 5114 Woodall Road P.O. Box 11318 Lynchburg, VA 24506-1318...
  • Page 60 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...

  • Page 61: Regulatory Information

    Type and Description of Equipment Valve Actuators Model Number LY Series Note Tested with Limitorque products only I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s). List as follows: (Signature) Barry Morse...
  • Page 62 Flow Control Division Limitorque Actuation Systems This page is intentionally blank. 10-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501...
  • Page 63 Flow Control Division Limitorque Actuation Systems Australian Distributor for Limitorque Acrodyne Pty Ltd 14/11 Havelock Road Bayswater, Victoria 3153 Australia Phone 03-8727-7800 Fax 03-9729-8699...

This manual is also suitable for:

Ly 1001 seriesLy 2001 seriesLy 3001 series

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